KUSSMAUL 091-84-005 User manual

INSTRUCTION MANUAL
KUSSMAUL ELECTRONICS CO., INC.
170 CHERRY AVE., WEST SAYVILLE, N.Y. 11796
10-19-96
TEL: in NY 631-567-0314 TOLL FREE: 800-346-0857 FAX: [phone]
ENGINE IDLER MODULE
PART OF A HIGH IDLE SYSTEM
3 YEAR WARRANTY
ENGINE IDLER
MODEL #091-84-005

INTRODUCTION
The 091-84-005 Engine Idler model is part of a high idle system that can be installed on
eithergasolineordieselengines.Thisdevicepermitsavehicleoperatortoincreaseengine
RPMto obtainmore alternatoroutput. Inorder tomove thethrottle mechanismor interface
with electronic controlled engines additional components are required.
ThismoduleinterfaceswiththeBrakePedalSwitch,Park/NeutralSafetySwitch,asolenoid
vacuumvalve,athrottleactuatorandinsomeinstallationsaVoltageMonitor.IthasHighIdle
"ON" and "OFF" pushbuttons on its front face allowing the operator to switch in and out of
HIGH IDLE when the vehicle is in Park or Neutral. An LED indicator on the front face is
illuminated when the engine is in HIGH IDLE.
DESCRIPTION

INSTALLATION
Typicalinstallationsongasolineanddieselenginesareillustratedin figures1 and2. Mount
actuatorandsolenoidvalveinanappropriatelocationandconnecttheactuatoroutputtothe
throttlemechanism.(Note:Theactuatorandsolenoidvalvemustbepurchasedseperately.
Becertain thattheball chainor othercouplingdoes notrestrictthrottle motionat fullclosed
throttle or wide-open throttle. Connect solenoid valve input to a source of vacuum for
gasoline engines or pressure for diesel engines. Pipe the solenoid valve output to the
actuator as illustrated in figure 1 or figure 2. Install wiring as shown.
OPERATION
The High Idler receives its power from the ignition switch and functions only when the
ignition switch is either "ON" or in the ACC. position. High Idle is automatically disabled
under any of the following conditions:
1. Operator depresses the "OFF" pushbutton on the Engine Idler
2. Operator depresses the brake pedal
3. Operator places the transmission into Drive or Reverse
4. Operator turns off the ignition switch

TEST PROCEDURE
1. With the transmission switch in PARK turn the ignition switch to the Accessory
position. The LED on the Engine Idler should remain OFF.
2.Pressthe"ON"switchontheEngineIdler.TheLEDontheEngineIdlershouldturn
ON.
3. Move the transmission to Drive or Reverse. The LED on the Engine Idler should
turnOFF.
4. Place the transmission in PARK and press the "ON" switch to turn the LED ON
again.
5. Depress the Brake Pedal. This should turn the LED OFF.
6. Start the engine and allow it to warm up with the transmission in PARK mode.
7.DepresstheON switchontheEngineIdlerand adjustthecouplingtotheactuator
and the stroke to obtain the desired engine RPM. Re-check the RPM by turning the
unit ON and OFF a few times.

FORD, in many installations uses a starter
solenoid which has one side of the coil
grounded.The neutral safety switch is then
placedinthesupplysideofthesolenoidcoil.
This configuration creates a considerable
voltage spike when the vehicle is started.
A diode must be placed across the starter
solenoidintheseinstallationstopreventdam-
age to the engine idler.
Seetheappropriatewiringdiagramfordiode
installationdetails.
FORDINSTALLATIONS
CAUTION

KUSSMAUL
ENGINE IDLER
ON
OFF
ENGINE IDLER INSTALLATION
FOR GASOLINE ENGINES WITH A VACUUM SOURCE
BATTERY +
NEUTRAL
SAFETY SWITCH
CLOSE IN
NEUTRAL/PARK
BRAKE
LIGHT
DIODE
On some vehicles install diode to
prevent emergency flasher or
turn signals from turning off the
engine idler
To +12 volts
thru accessory
position of
Ignition switch
Figure 1
1 amp fuse
BRAKE SWITCH
IN
OUT
091-84-VV
SOLENOID
AIR VALVE
TO VACUUM
SOURCE
VACUUM
ACTUATOR
091-84-VA
Stroke adjust
CHAIN,
CONNECT TO
THROTTLE LINKAGE

KUSSMAUL KUSSMAUL
ENGINE IDLER
V
OLTAGE MONITOR
ON LOW
OFF HIGH
INSTALLATION AND WIRING DIAGRAM
IN
OUT
091-84-VV
BATTERY +
BRAKE
LIGHT
DIODE
On some vehicles install diode to
prevent emergency flasher or
turn signals from turning off the
engine idler
To +12 volts
thru accessory
position of
Ignition switch
Figure 2
1 amp fuse
V
OLTAGE MONITOR & ENGINE IDLER
BRAKE SWITCH
FOR ENGINES WITH A VACUUM SOURCE
Starter
Solenoid
Connect 1N4004
as shown to suppress
starter solenoid transient
+12 volts from ignition switch
in "START" position
NEUTRAL
SAFETY SWITCH
CLOSED IN NEUTRAL OR PARK
NOTE:
Some engines have one
side of starter solenoid at
ground and the neutral
safety switch in the supply
side.
These must have a diode
installed across the starter
solenoid as illustrated.
This is particularly true of
FORD products
SEE NOTE:
VACUUM
ACTUATOR
091-84-VA
Stroke adjust
CHAIN,
CONNECT TO
THROTTLE LINKAGE
TO VACUUM
SOURCE
SOLENOID
AIR VALVE

KUSSMAUL KUSSMAUL
ENGINE IDLER
V
OLTAGE MONITOR
ON LOW
OFF HIGH
BATTERY +
NEUTRAL
SAFETY SWITCH
CLOSE IN
NEUTRAL/PARK
BRAKE
LIGHT
DIODE
On some vehicles install diode to
prevent emergency flasher or
turn signals from turning off the
engine idler
To +12 volts
thru accessory
position of
Ignition switch
Figure 2
1 amp fuse
VOLTAGE MONITOR & ENGINE IDLER
BRAKE SWITCH
INSTALLATION AND WIRING DIAGRAM
FOR DIESEL ENGINES WITH AIR PRESSURE AVAILABLE
091-84-PV
SOLENOID
AIR VALVE
TO PRESSURE
SOURCE
PRESSURE
ACTUATOR
OUT
IN
CONNECT TO THROTTLE
(PRESSURE PULLS THROTTLE)
STROKE ADJ. SCREW

INSTALLATION RECORD & WARRANTY
Date Installed
Installed By
Vehicle Identification
Vehicle Owner
WARRANTY
All product of Kussmaul Electronics Company Inc. are warranted to
be free of defects of material or workmanship. Liability is limited to repair-
ing or replacing at our factory, without charge, any material or defects
which become apparent in normal use within 3 years from the date the
equipment was shipped.
Kussmaul Electronics Company, Inc. shall have no liability for dam-
ages of any kind to associated equipment arising from the installation and
/or use of the Kussmaul Electronics Company, Inc. products. The pur-
chaser, by the acceptance of the equipment, assumes all liability for any
damages which may result from its installation, use or misuse, by the
purchaser, his or its